Perforated-Core Composite Panel Delamination Resistance
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Solution Overview
Problem
Existing composite panels are prone to delamination under bending forces, leading to deteriorated mechanical characteristics, and current reinforcement methods are costly and complex, increasing industrial investment and production time.
Innovation Solution
The composite panel features recesses shaped in the core to receive solidified binding material, which acts as a rooting mechanism between the skins and core, enhancing the bond and preventing delamination, while allowing for efficient production using needling or other processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical connection between skin and core is created using complex seam-making machines, then delamination resistance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The core is made porous by creating recesses that receive binding material, allowing the skin to mechanically interlock with the core through the porous structure rather than through complex external seam-making machines
Solution Approach 2:
The complex mechanical seam-making system is replaced by a simpler system where recesses are formed in the core and binding material is injected to create mechanical connection, substituting complex machinery with a material-based solution
2Reliability
If complex seam-making operations are performed before resin impregnation, then delamination resistance is improved, but manufacturing time increases
Solution Approach 1:
The formation of recesses and the resin impregnation process are merged into a single manufacturing step, where recesses are formed in the core and immediately filled with binding material during the impregnation process, eliminating separate seam-making operations
Solution Approach 2:
The recesses are pre-formed in the core before skin attachment, preparing the structure in advance to receive binding material during impregnation, thereby streamlining the overall manufacturing process
3Reliability
If uniform reinforcement is applied across the entire panel, then delamination resistance is improved, but manufacturing cost increases
Solution Approach 1:
The recess density is varied locally across the panel, with higher density in areas subject to higher stresses and lower density in less critical areas, optimizing binding material usage while maintaining delamination resistance where needed
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly improves the mechanical properties and resistance to delamination of the panel without increasing production costs, allowing for customizable reinforcement density and pattern to match specific stress areas, thus providing a cost-effective and robust composite panel.
Implementation Method 1
by needling, recesses are formed in the core directly by at least one of its faces
Implementation Method 2
a core placed in the space between the sheets and connected to them by a solidified binder material
Implementation Method 3
The skins comprise a fibrous framework impregnated with a resin which gives these skins a certain intrinsic rigidity as well as a bond with the core
Data Source
Figure 1~7
Figure 4~6
AI summary
The invention relates to a composite panel (1), comprising two fibrous plies (21) and a core (3) placed in the intervening volume between the plies (21) and connected together by a solidified binding material (22), characterized in that openings (6) are made in the core (3), via at least one of its faces (31; 32), so as to exclusively receive solidified binding material (22). The invention also relates to a device and to a method for manufacturing such a composite panel. Use for inexpensively producing particularly strong composite panels, with the possibility of having a very wide range of options as regards the constituents of the core and of the fibrous plies.